Line Element Lead-Through with Support Structure

ABSTRACT

In order to produce a line element lead-through that is resistant to fire and flue gas for simple installation into one or more paneled drywalls, whereby the line element lead-through can be used in a matching component opening and is also sealed against fire and flue gas when empty, a line element lead-through is suggested with a molded element closed on at least one side of an elastically deformable intumescent material as a sleeve, especially formed as a truncated cone or a cylinder, with the criterion that the opening cross section of the sleeve corresponds to maximum 60% of the cross section of the component pass-through. Embedded within the molded element is a support structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 13/403,396, filed Feb. 23, 2012, which claimsbenefit from and priority to German Patent Application No. DE 10 2011004 575.9, filed Feb. 23, 2011.

The present application is also a continuation-in-part of U.S. patentapplication Ser. No. 13/300,321, filed ______, which claims benefit fromand priority to German Patent Application No. DE 10 2010 044 161.9,filed Nov. 19, 2010.

The above-identified applications are hereby incorporated herein byreference in their entirety.

BACKGROUND OF THE INVENTION

For fire protection purposes, lead-throughs of line elements, e.g.,pipes or cables or the like, through walls or ceilings must be providedwith a so-called barrier or a fitting in order to prevent flames andespecially smoke and poisonous gases from spreading from room to room orbetween floors if there is a fire.

In the fittings of rooms, the lead-throughs and lead-through openingsfor cables, pipes and the like are problematic since they were notinstalled until after completion of the entire installation, i.e.,retrofit, and also can only be retrofitted after the routing of thecables and pipes.

In many cases, the wall lead-throughs either remain open or are onlyclosed in a preliminary manner with mineral wool or stone wool cut tosize. In order to pass the cables and lines through, these stoppers mustbe removed again, whereby after the lines and cables are passed through,the lead-throughs have to finally be closed using fire-resistant mortar,stone wool or mineral wool inserts.

However, it is often necessary that lines must be routed long after theinstallation is complete. This is the case, above all, when new roomsare produced in older buildings. For this purpose, drywall is oftenused. However, even during remodeling and/or renovation of publicbuildings, schools, hospitals, office buildings and special buildings,drywalls are created more and more frequently. The firewalls are oftensuch drywalls. The drywalls often are made of sandwich-type plasterboardand are hollow or filled with mineral wool. Therefore, it is possible toroute installations, especially distribution of cables, in these walls.

In addition to the classic cable lead-throughs, cables are frequentlythreaded out from these walls. For smaller individual cables, nocomplicated fire protection measures must be taken. Sealing with plasteror sealing compound is sufficient. Thicker cables, small cable bundles,empty pipes or several individual cables would have to be sealeddepending on the configuration, with the approved fire protectionsystem. The rules on how all of this must be designed are different, sothe skilled tradesman is uncertain during the installation of how theline lead-through must be sealed. In addition, to date it was necessaryto close the line lead-throughs so that they are sealed against fire andflue gas immediately after installation of the cables. During productionof lead-throughs in fire-resistant components that are only equippedwith lines much later, the problem resulted that up to the time theopenings are equipped they have to be sealed so that they are fire-tightand sealed against flue gas. Equipping the openings required severalwork steps for leading the lines through and sealing the spaces thatdeveloped again so they are sealed against fire and flue gas. To date,this has not been possible using simple devices.

The cable boxes that were previously commonly used are complicated,especially when later fitting them with cables and/or pipes. Thedifficulty arises in that the (subsequent) openings have to be sealedagainst flue gas.

EP 0321664 discloses a seal for lead-throughs in walls, ceilings, etc.that is sealed against flue gas and fire that includes a molded elementdesigned as a conical stopper of an elastically deformable intumescentmaterial. The stopper is deformable with dimensional stability so it canbe pressed through the lead-through and can seal it tightly. In thestopper, lead-through holes can be formed for sealed holding of pipesand/or lines. However, the lead-through holes must be adapted to therespective pipe and/or line diameters, in order to be able to sealtightly. Thus, a considerable amount of work is required for subsequentequipping of the stopper with cables or lines, which makes the systeminflexible and susceptible to errors. When they are equipped withseveral cables or lines, the problem also results that because of itsthickness the material does not seal the gussets and gaps that occur, sothese have to additionally be sealed with special sealing compounds.

An arrangement for a lead-through of a long molded part through a wallthat is sealed against flue gas is known from EP 2 273 637 A2. The fireprotection element includes a sleeve of intumescent material or aplastic sleeve with an inner and/or outer coating of intumescentmaterial. However, the arrangement itself is not sealed against fluegas, so it cannot be used if the component lead-through is not equipped.In addition, the arrangement has the disadvantage that equipping it withseveral long molded parts (line elements) is impossible because of theless flexible sleeve.

Generally, compliance with the 60% rule for cable seals with officialapproval causes great problems, according to which only up to max. 60%of the opening cross section must be filled with cables for openings infirewalls and ceilings. In practice, this is difficult to evaluate whenthis limit is reached or exceeded.

BRIEF SUMMARY OF THE INVENTION

Some embodiments according to the present invention provide a lineelement lead-through that is resistant to fire and flue gas for simpleinstallation into one or more paneled drywalls, whereby the line elementlead-through can be used in a matching component opening and is alsosealed against fire and flue gas when empty. A line element lead-throughcan be provided with a molded element closed on at least one side of anelastically deformable intumescent material as a sleeve (e.g.,configured as a truncated cone or a cylinder) characterized by acriterion that the opening cross section of the sleeve corresponds tomaximum 60% of the cross section of the component pass-through.

In some embodiments, embedded within the molded element is a supportstructure. The support structure can be, for example, a thin, flat gridstructure formed of at least glass fibers as supporting elements. Thegrid structure can be embedded (e.g., embedded completely) in a foamedbody of the molded element.

One or more embodiments provide a line element lead-through that issimple in design, easy to handle and cost-effective for lead-throughs incomponent parts like fire protection ceilings and walls that can beinstalled in a simple way after creation of the components and permits asealing of the lead-throughs that is fire and flue gas resistant even ifthe lead-throughs are not equipped.

According to one or more embodiments, the line element lead-through ischaracterized by a molded element of an elastically deformableintumescent material designed as a sleeve and closed on at least oneside.

One or more embodiments provide a fire protection element having afoamed body, which is made at least partially of an ash-forming and, ifapplicable, intumescent mixture.

Fire protection elements made of, for example, foamed material withintumescent additives can be used, for example, to seal cable and pipelead-throughs so they are flue-gas-proof as well as heat andfire-resistant. The foamed material according to one or more embodimentsserves as a matrix for fire-protection additives. Fire protectionelements with a rectangular block shape, for example, are used forbulkheading large lead-throughs. In one or more embodiments, the fireprotection elements are made of, for example, a polymer matrix intowhich various additives such as intumescent materials, ash-crust formersand ash-crust stabilizers are introduced.

In one or more embodiments, the heat and fire-resistant properties ofthe fire protection elements are produced in the event of a fire inwhich the fire protection element burns away on the outside and forms alayer of ash. The layer of ash then provides thermal insulation. Anobject of one or more embodiments is that the layer of ash is as stableas possible so that it does not fall off from the rest of the fireprotection element. The object can be achieved, at least in partaccording to one or more embodiments, by chemical additives in thefoamed material, for example. In the case of large fire protectionelements or large lead-throughs that are to be sealed, for example,adequate mechanical stability of the ash crust itself as well assufficiently stable adherence of the ash crust to the still unburnedportion of the fire protection element is preserved even when there isadvanced fire development.

In the case of larger fire protection elements such as fire protectionblocks, for example, it is frequently observed that when there isadvanced burn-off of the fire-protection block, the ash that has alreadyformed falls off or the still unburned portion of the fire-protectionblock falls out of the bulkhead. This can be attributed for one to thematrix beginning to melt in the case of a fire, whereby the intumescenceof the additives is initially able to take place. However, the zone ofthe liquid matrix weakens the bond with the already formed ash crust. Inaddition, the intumescence can contribute to the still unburned portionof the fire-protection block being pushed out of the bulkhead. This canbecome problematic particularly in the case of large ceiling bulkheads.

The weakening of the bond between the ash crust and the still unburnedportion of the fire-protection block can become a problem in the case ofthe hose stream test required in the U.S., in which the crust must beable to withstand a strong water stream after the fire.

It is an object of one or more embodiments to strengthen the bondbetween the ash crust and the unburned portion of the fire protectionelement. For this purpose, applying a wire mesh on the outside of thefire protection element or attaching the fire protection element to awire mesh are known, which prevents the layer of ash from falling off.Especially with respect to ceiling bulkheads, it is advantageous thatthe ash does not detach from the substrate and fall off the bulkhead inthick layers. Then the underlying layer would namely be burned, whichwould reduce the mechanical strength of the fire protection element aswell as its resistance time against burn-through. Crossbars,intermediate layers made of glass-fiber fabric or the like, which closethe fire protection element at the bottom, are also known.

An object of one or more embodiments is to improve a fire protectionelement such that the ash crust originating in the event of a fire iskept on the fire protection element in the most stable manner possible.

The fire protection element according to one or more embodimentsfeatures at least one carrier component, which is designed as a thin,flat part. In some embodiments, the carrier component can be aprefabricated carrier component embedded in the body, which is coveredby the body on one of its two flat sides, preferably completely covered.

The fire protection element is not defined as a specific form. Accordingto one or more embodiments, the component may assume any imaginable formwhich is used for bulkhead lead-throughs for the purpose of fireprotection. Forms that are a possibility for this are stones in the formof bricks, mats, plugs for sealing round openings, wall lead-throughsfor individual cables (bushings) just to name a few as examples.

In one or more embodiments, the carrier component is fastenedsubsequently to the fire protection element. It may be affixed to thefire protection element in a manner known to a person skilled in the artso that the carrier component is covered on one side by the body of thefire protection element.

In one or more embodiments, the fire protection element does not provideany carrier components or auxiliary means such as wire mesh, supports orglass-fiber fabric that are subsequently attached on the outside. Ratherthe stability of the ash crust is achieved by a carrier componentembedded in the body, preferably one that is completely embedded. In oneor more embodiments, a fire protection element has a foamed body, whichis made at least partially of an ash-forming and, if applicable,intumescent mixture, and at least one prefabricated carrier componentembedded in the body. In one or more embodiments, the carrier componentcan be a thin, flat part, which is covered by the body on at least oneflat side, preferably on three sides, especially preferably completely.

In one or more embodiments, the carrier component is not a thick,voluminous component, but a flat part whose thickness is preferably amaximum of approximately 2 mm. This thickness can be measuredperpendicular to the main extension direction of the part. This carriercomponent also differs in this respect from the honeycomb-shapedcomponent provided in German Patent Document No. DE 10 2005 013 724 B4.The fire protection element according to one or more embodiments is veryeasy to produce in contrast to the honeycomb-shaped component; inparticular, the formation of large bubbles in the body from numerousto-be-filled chambers that are separated from each other by bulkheads isruled out because of the thin, flat geometry of the carrier component.

In one or more embodiments, the flat part can be formed by placingfibers or fibrous elements, which are not necessarily connected to oneanother, adjacent to one another. The threads can be integrated thereinin the direction of the burning away of the component, because otherwisethe effect according might not be achieved.

In one or more embodiments, so that in the event of fire the carriercomponent has the best possible connection between the already formed(e.g., intumescent) ash crust and the still unburned portion of the fireprotection element, it should be covered by the body on at least threesides, for example, or on all sides. The carrier component can form anouter side of the fire protection element. The carrier componentpreferably does not extend up to the outer side of the body.

In one or more embodiments, the carrier component can be a flexiblepart, in particular, which is designed not to be rigid, but imparts thefire protection element with stability once it is embedded in the bodyduring foaming.

The carrier component in one or more embodiments has a structure whichensures a connection between the ash crust and the still unburnedportion of the component beyond the melting zone. This can be achievedby fibers or threads arranged side-by-side like a mat. According to oneor more embodiments, the carrier component includes a grid structurethrough which the foam extends.

Some embodiments provide that a fabric is used as the carrier component.

Some embodiments provide that the carrier component has a mesh size andthe threads of the fabric have a thread size, which are in a specificratio to each other. The thread size does not relate to the size of anindividual thread, but to the thickness of the fabric. The ratio of themesh size to the thread size should be in the range of approximately 1to 200, in particular, in the range of approximately 12 to 18.

The threads of the fabric can have a thread size between approximately0.05 mm and approximately 1 mm in some embodiments; betweenapproximately 0.1 mm and approximately 0.8 mm in other embodiments; andapproximately 0.2 mm in yet other embodiments. The fabric can have amesh size of approximately 1 mm to approximately 50 mm in someembodiments, approximately 2 mm to approximately 20 mm in otherembodiments, and approximately 3 mm to approximately 5 mm in yet otherembodiments.

According to one or more embodiments, the carrier component is made of,for example, a temperature-resistant material (e.g., an inorganicmaterial). Temperature-resistant within the scope of one or moreembodiments means that the materials have a higher melting point thanthe matrix material. Such materials include, for example, carbon,ceramic, basalt, mineral fibers, glass fibers, natural fibers andcomposites with plastics. Even perforated sheeting, expanded metals,fabric made of metals such as aluminum, which are created in such a waythat they do not impair the flexible properties of the fire protectionelement, may be used as the carrier component according to one or moreembodiments.

One or more embodiments provide that materials be used as the carriercomponent, which permit a simple processing, such as cutting the fireprotection element to size with a carpet knife.

Although some embodiments provide for fireproof carrier components,depending upon the thickness of the layer between the outer side of thefire protection element and the carrier component, other embodimentsprovide that combustible materials can be used for the carriercomponent. In this case, it may be advantageous that the layer of ashthat develops in the event of fire is designed to be thick enough.

For clarification purposes, some embodiments will be described moreprecisely on the basis of a fire-protection block without restrictingthe present invention to a fire-protection block.

In some embodiments, the arrangement of the component in the fireprotection element is not limited as long as the carrier component isembedded in the direction of the burning of the fire protection element.In one or more embodiments, the carrier component may be arranged asclose as possible to the outer side of the fire protection element. Itmay extend, for example, along at least one outer side of the body. Inthe case of a fire protection element in the shape of a rectangularsolid, for example, which is installed in a lead-through in such a waythat its longer side extends into the lead-through so that the burningtakes place starting from the smaller side surface of the rectangularsolid, the carrier component should extend at least along the basesurface of the rectangular solid.

Some embodiments provide that the carrier component extends completelyalong an outer side. Other embodiments provide that the carriercomponent extends along several outer sides of the body.

Alternatively or additionally, a component that is embedded in thecarrier component in a bent or kinked manner can be provided. Forexample, the carrier component may run in a wavy manner or be bent in aV-shaped manner. In addition, overlapping or intersecting carriercomponents may also be used.

These and other advantages, aspects and novel features of the presentinvention, as well as details of one or more illustrated embodimentsthereof, will be more fully understood from the following descriptionand drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a line element lead-through according to a first embodimentaccording to the present invention.

FIG. 2 shows a cross section through the line element lead-through shownin FIG. 1.

FIG. 3 shows a cross section through a line element lead-throughaccording to FIG. 1 inserted in a component opening equipped with acable.

FIG. 4 shows a line element lead-through according to a secondembodiment according to the present invention.

FIG. 5 shows a cross section through a line element lead-throughaccording to FIG. 4 inserted in a component opening and equipped with acable.

FIG. 6 shows a first embodiment of a carrier component according to thepresent invention.

FIG. 7 shows a second embodiment of a carrier component according to thepresent invention.

FIG. 8 shows a third embodiment of a carrier component according to thepresent invention.

FIG. 9 shows a fourth embodiment of a carrier component according to thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

In the sense of one or more embodiments of the present invention, thefollowing definitions are used:

-   -   “elastically deformable” means that the material of which the        line element lead-through is made of is sufficiently elastic so        that pressing it together is possible without problems, i.e.,        without exerting a great deal of force, say by hand, and the        line element lead-through again assumes its original shape;    -   “form fitting” means that the line element lead-through contacts        the inner wall of the component lead-through directly not only        in one spot but over a certain area and forms a contact surface;    -   “intumescent material” means an intumescent foam material that        carbonizes at temperatures starting at approximately 150° C.        and/or the effect of flame with multiple increases in volume; an        intumescent material according to one or more embodiments of the        present invention that can be used is described, for example, in        DE 3917518 or U.S. Pat. No. 3,574,664;    -   “ash forming” means that the foam carbonizes without significant        intumescence;    -   “line element” means cables like electrical cables, lines, empty        pipes, pipes, bundles of lines or pipes and the like;    -   “seal” means that in a one-piece hollow molded element, the base        and/or the cover surface is closed;    -   “opening cross section” means the cross section of the line        element lead-through that can be equipped with cables.

Some embodiments according to the present invention relate to a lineelement lead-through that is sealed against fire and flue gas forpassages in walls and ceilings. Some embodiment relates to a linelead-through of an intumescent foam. Some embodiments relate to a linelead-through with a support structure embedded (e.g., completelyembedded) therein.

The line element lead-through according to one or more embodiments ofthe present invention is advantageously formed so that it can be slidmanually into a circular or oval passage through the wall. Because of aslight excess dimension of the shape designed as a sleeve and theelastically deformable material, after sliding in, the line elementfeed-through contacts the inner wall of the passage with a specifiedpressure and seals it. More precisely, this is achieved when the outerdiameter of the line element lead-through is somewhat larger than thatof the diameter of the component opening. In some embodiments, the outerdiameter is approximately 1 mm to approximately 5 mm larger than thediameter of the component opening. In other embodiments, the outerdiameter is approximately 2 mm to approximately 3 mm larger than thediameter of the component opening.

The elastically deformable material of which this is made of also makespossible sealing against fire and flue gas after the introduction of atleast one line. The cables passed through compress the pierced wall ofthe line element lead-through and thus generate an extensive sealingagainst flue gas.

The general construction approval no. Z-19.15-349 prescribes that theentire permissible cross section of the installation, related to therespective outer dimensions, must be no more than 60% of the roughopening in total, the so-called 60% rule. Accordingly, the line elementlead-through according to one or more embodiments of the presentinvention is designed so that the free opening of the truncated conecorresponds to the opening cross section and thus 60% of the crosssection of the component opening. Thus, the opening of the truncatedcone can be filled completely with line elements without violating the60% rule. Cables and empty pipes are led through individually or asbundles up to this max. inner diameter.

According to one or more embodiments of the present invention, themolded element is made of an ash-forming and/or intumescent foam. Thismakes it possible to create the component lead-throughs prophylacticallyand in spite of them being filled, sealing them at temperatures startingfrom approx. 150° C. and/or with the effective flame against passage ofair and/or smoke and only passing the line elements through whennecessary.

In one or more embodiments, the line element lead-through is designed asone piece.

In one or more embodiments, the line element lead-through is provided onthe base surface with a flange-like edging that points radially outward.This prevents, for example, sliding the line element lead-through toofar into the opening, preventing the line element lead-through, forexample, from falling into the hollow space of drywalls. In addition,the edging additionally seals the component opening in the case of afire whether it is filled with a line element or not.

According to one or more embodiments of the present invention, themolded element of the line element lead-through is closed on its coversurface in order to form a seal. In general, it does not matter whetherthe base or the cover surface of the molded element is closed, or both.Both permit a sealing of the component passage that is sealed againstfire and flue gas. However, a molded element that is closed on one sideis simpler and less expensive to manufacture without any sacrifice toits functionality, so this embodiment may be highly preferred whereby itis especially preferred if the molded element is closed on its coversurface.

The wall thickness of the molded element should be selected depending onthe size of the component passage to be sealed and accordingly the sizeof the line element lead-through to be used so that, for example, thereis no negative effect on the flexibility of the line elementlead-through and, for another, a form-fitting seal of the componentpassage is ensured. However, the wall of the molded element must be atleast thick enough so that the cross section of the free opening to beequipped is no greater than 60% of the cross section of the componentopening. If the wall thickness is too great, the line elementlead-through is not form-fit on the component passage and the outer wallof the component, which means that sealing against flue gas is no longerensured.

Preferably the wall thickness d₁ is approximately 5 mm to approximately20 mm, more preferably approximately 8 mm to approximately 16 mm, but atleast thick enough so that the 60% rule is not violated. For a hole ofapproximately 4 cm Ø (diameter), the area of approximately 12.6 cm² mustbe filled approximately 7.5 cm² according to the 60% rule, thiscorresponds to a 0 of approximately 3.1 cm. Thus the wall thickness mustbe at least approximately 5 mm. For a hole with approximately 6 cm Ø,the wall thickness would thus be approximately 7 mm and forapproximately 10 cm Ø it would be approximately 11 mm.

With a wall thickness of less than approximately 5 mm, the material ofthe line element lead-through is not adequate to create adequateintumescence and an adequately stable ash crust for sealing thecomponent passage in the case of fire. In addition, during (subsequent)equipping of the line element lead-through with line elements, themolded element would be susceptible to cracks so sealing against fluegas could no longer be ensured.

The wall thickness d₂ of the seal is less than the remaining molded partin order to make it easier to pierce it with a line element. However, itmust be selected such that after piercing, the seal lies form-fit on theline element so that in case of fire an adequate sealing against fluegas is ensured. Preferably the wall thickness is approximately 2 mm toapproximately 8 mm, more preferably approximately 3 mm to approximately6 mm.

In one or more embodiments of the present invention, the seal haspredetermined breaking points to make it easier to pierce the seal. Thespecified breaking points are distinguished in that the material of themolded element is thinner at these points than the wall, preferablybetween approximately 1 mm and approximately 4 mm, and more preferablybetween approximately 2 mm and approximately 3 mm. In addition, thesespots have a specific shape. For example, the specified breaking pointscan be circular, star-shaped or cross-shaped, whereby the geometry ofthe specified breaking point is not restricted. For example, thespecified breaking point can also include several individual specifiedbreaking points, circles of different diameters lying inside each other.

In a preferred embodiment, the molded element is designed as a truncatedcone. Because of this, there is a certain flexibility when the lineelement lead-through is not completely filled, say with only one lineelement or a line element with a diameter that is smaller than theopening diameter of the line element, without having a negativeinfluence on the sealing against flue gas.

In one or more embodiments, the seal is designed as a membrane.

In an embodiment according to the present invention, the molded elementis designed as a truncated cone. Because of the shape designed as atruncated cone, a case is achieved in which the user has a certainamount of freedom during selection of the line elements so that a lineelement lead-through can hold and seal at least one line element ofdifferent thickness/diameter.

In another alternative embodiment, the molded element is designed as acylinder. In this way, better sealing against flue gas can be achievedsince the longish element can better compensate or bridge unevenness inthe walls of the component passage.

The length l of the molded element is preferably approximately 3 cm toapproximately 6 cm, and more preferably approximately 3.5 cm toapproximately 5 cm, no matter whether it is designed as a truncated coneor a cylinder.

On its outside, the cylindrical molded element preferably has at leastone bead running around it radially that is arranged at a distance fromthe flange-like edging. When there are several beads, these are alsoarranged at a distance from each other. The (first) bead is arranged ata distance from the flange-like edging so that with a sandwich-typeplasterboard, a lock is formed directly behind it that prevents or willmake it more difficult for the line element lead-through to fall out orbe pulled out unintentionally when the line element is pulled through orif there is a light pull on the line element lead-through. In Germany,the thickness of a standard sandwich-type plasterboard panel isapproximately 12.5 mm and in the USA approximately 16 mm, so thedistance of the (first) bead from the flange-like edging isapproximately 12.5 mm or approximately 16 mm, respectively, startingfrom the edge of the flange-like edging contacting the component. Ifthicker walls are required, generally two (double panels) or more of thesandwich-type plasterboards are placed behind each other. In order toprevent pulling it out unintentionally from the double paneled wall, asecond bead is provided that according to one or more embodiments of thepresent invention is arranged at a distance from the first bead so thatthe distance of the second bead with respect to the flange-like edgingis the thickness of the paneling, namely approximately 25 mm orapproximately 32 mm, respectively, starting from the edge of theflange-like edging contacting the component. If no flange-like edging isprovided, the distances are measured from the front edge of the lineelement lead-through.

In axial direction, the bead has a thickness from approximately 4 mm toapproximately 6 mm. The thickness in radial direction is approximately 2mm to approximately 4 mm.

In one embodiment of the cylindrical molded element, the seal in themolded element is mounted at a distance from the end that is oppositethe opening, i.e., that is located in the component hole in thecomponent after introduction of the line element lead-through. The partof the molded element projecting beyond the seal then forms a guide,which makes it easier to pass line elements from the inside of thedrywall.

The molded element is manufactured using mold-foaming with reactionfoams (RIM) according to DE 3917518, e.g., with Fomox® fire-resistantfoam or with the material HILTI CP 65GN that forms an insulating layer.Materials that can be used for the purposes of one or more embodimentsof the present invention are known from EP 0061024 A1, EP 0051106 A1, EP0043952 A1, EP 0158165 A1, EP 0116846A1 and U.S. Pat. No. 3,396,129A aswell as EP 1347549 A1. Preferably the molded element is made ofpolyurethane foam capable of intumescence as known from EP 0061024 A1,DE 3025309 A1, DE 3041731 A1, DE 3302416 A and DE 3411 327 A1. Theabove-reference applications are hereby incorporated herein by referencein their entirety.

Exemplary embodiments according to one or more embodiments of thepresent invention will be explained in the following with the use of thedrawings.

FIG. 1 shows a line element lead-through of a molded element 1 designedas a truncated cone with a flange-like edging 2 that points radiallyoutward according to one embodiment of the present invention in whichthe base surface of the truncated cone forms the opening 3 and theclosed cover surface of the truncated cone forms the seal 4. In thisfigure, the specified breaking point 5 in the form of a star can be seenthat is designed on the seal 4.

FIG. 2 shows the truncated cone shape of the molded element 1 with alength l, wherein the material thickness d₁ of the edging 2 is notincluded, a wall thickness of the molded element d₁, and a wallthickness d₂ of the seal 4. The thinner specified breaking point 5 thatis arranged in the center of the seal is also indicated opposite thewall thickness d₂ of the seal 4.

FIG. 3 shows the barrier of an opening 7 in a component 6 with lineelement lead-through according to FIG. 1 according to one or moreembodiments of the present invention, through which a line element 8 inthe form of a cable is passed. From the embodiment shown in FIG. 3 inwhich the outer diameter of the molded element 1, in which the edging 2is not considered, is slightly larger than the diameter D of thecomponent opening 7, it is clear how the excess dimension of the outerdiameter of the molded element leads to a greater contact surface 10between the inner wall 9 of the component opening 7, whereby goodsealing against flue gas is achieved, and on the other, a frictionfitting self-locking of the line element lead-through is achieved. Thus,the line element lead-through can be fastened adequately tightly in thecomponent opening 7 without additional tools, whereby falling out isprevented and unintended pulling out is made more difficult. Inaddition, it can be seen how the seal 4 seals the line element 8.

FIG. 4 shows a line element lead-through of a molded element 1 designedas a cylinder with a flange-like edging 2, an opening 3, a seal 4 andtwo beads 11 and 12 according to a second alternative embodimentaccording to the present invention.

FIG. 5 shows the barrier of an opening 7 in a component 6 that is madeof two sandwich-type plasterboards (double paneled drywall) with theline element lead-through according to the embodiment according to FIG.4 when equipped with a line element 8. It can be seen from this that thesecond bead 12 engages behind the second plasterboard panel and thusforms a lock against unintentional pulling out of the line elementlead-through. Because of the elastically deformable material of whichthe molded element 1 is made of, the first bead 11 is compressed,whereby additionally a clamping of the line element lead-through withthe inner wall 7 of the component opening 6 is achieved.

In some embodiments, the molded element 1, for example, designed as atruncated cone or a cylinder as illustrated in FIGS. 1-5 can benefitfrom incorporating a carrier component 18 such as, for example, a meshor grid formed of glass fibers, for example, that are embedded in themolded element 1. The carrier component 18 can be entirely embedded inthe molded element 1. The carrier component 18 can alternatively bepartially embedded in the molded element 1 such that an outer surface ofthe carrier component 18 is exposed on the outer surface of the moldedelement 1. The carrier component 18 can be in the shape of a truncatedcone and embedded in the molded element 1 configured as a truncated coneas illustrated in FIG. 2. The carrier component 18 can alternatively bein the shape of a cylinder and embedded in the molded element 1configured as a cylinder as illustrated in FIG. 4. The grid may extendfrom one end of the molded element 1 to the other side of the moldedelement 1. In some embodiments, the grid does not extend into the flangeedges 2.

In some embodiments, the carrier component 18 provides a supportstructure for the molded element 1. In addition, if the molded element 1is exposed to heat and produces ash crust, the ash crust is more likelyto stay attached to unburned portions of the molded element 1 becausethe ash crust and the unburned portions are connected by the carriercomponent 18. In addition, the carrier component 18 controls theexpansion of the molded element 1 when exposed to heat. The intumescentfoam or mixture of the molded element 1, when exposed to heat, expands.However, the carrier component 18 controls the expansions so that themolded element 1 does not expand in an unrestrained and undirectedmanner, thus reducing the negative effects on the structural integrityof the molded element 1.

Although generally discussed, at times below, with respect to a fireprotection element 13, for example, in the form of a rectangular block,the carrier component 18 can be used with other shapes and otherapplications such as, noted above, with respect to a line elementlead-through of a molded element 1.

FIG. 6 shows a fire protection element 13. In some embodiments, the fireprotection element 13 can be used in ceiling openings to seal cableand/or pipe lead-throughs. In some embodiments, the fire protectionelement 13 can be in the form of a line element lead-through of a moldedelement 1 designed as a truncated cone or as a cylinder as illustratedin FIGS. 1-5.

Referring to FIG. 1, the fire protection element 13 has a rectangularblock-shaped body having several outer sides, more precisely, sidesurfaces 15 as well as an upper side and a lower side 14 or 16.

In some embodiments, the fire protection element 13 can be made, inpart, of an ash-forming and, if applicable, intumescent mixture, whichis added to a foaming substance. This mixture together with the foamingsubstance, preferably polyurethane, produces a foamed body after foamingand hardening. One or more carrier components 18 can be embedded in thisfoamed body. FIG. 6 depicts a carrier component 18 which has a U-shape.However, the present invention need not be so limited in shape orapplication.

A very thin, flat, prefabricated component can be used as the carriercomponent. A commercially available reinforcement fabric made of textileglass material can be used.

In some embodiments, the carrier component is designed to be flexible,in particular not inherently rigid.

In some embodiments, the carrier component includes a fabric havingseveral threads 20 which have a thickness of between approximately 0.1and approximately 1 mm, preferably approximately 0.2 to approximately0.3 mm.

The carrier component 18 has numerous openings, the size of which isdefined by a so-called mesh size. The mesh size is between approximately1 and approximately 50 mm, preferably approximately 3.5 to approximately4.5 mm. The mesh size is defined as the smallest distance betweenadjacent grid elements (e.g., threads in the case of fabric). The meshsize is designated as “a” in FIG. 6.

The mesh size a is proportional to the thread size, and specifically itsratio is approximately 1 to 200, in particular approximately 10 to 50and especially preferably approximately 12 to 18.

Inorganic and/or organic materials or even combustible materials can beused as the material for the carrier component. Materials like carbon,ceramic, basalt, mineral fibers, glass fibers, natural fibers andcomposites with plastic in use as well as pure plastics which have ahigher melting point than the matrix material can be used.

In some embodiments, the carrier component 18 is so thin and flexiblethat it may be cut with a knife, in particular a type of carpet knife orwith a pair of scissors. Ideally, the carrier component is produced froma glass-fiber material, wherein metal may also be used however.

The production of the fire protection element will be explained furtherbelow.

In some embodiments, the carrier component 18 is cut and then bent intoa U-shape, for example.

Referring to FIG. 6, the two sides 30 as well as a base surface 32 areprovided, which are assigned to two side surfaces 15 as well as thelower side 16.

The carrier component 18 is inserted into a mold part 34, which has asurrounding frame as well as a base. The size of the carrier component18 is selected such that the surfaces 30 and 32 are somewhat smallerthan the associated surfaces in the recess of the mold part. Afterputting the carrier component 18 into the recess 36 in the mold part 34,the carrier component 18 is positioned in such a way that it is at ashort distance from the mold part 34 on all sides.

Then a flowable mixture is poured into the recess 36, wherein possiblyeven beforehand, prior to inserting the carrier component 18, a portionof this mass could be introduced in the region of the base of the moldpart 34. Finally, the mold part is closed on the upper side by a cover(not shown). The introduced mass is, for example, polyurethane with anash-forming and, if applicable, intumescent mixture. The mass foams upand penetrates the carrier component 18 because of the numerousopenings. After hardening, the carrier component 18 is preferablycompletely inside the formed, foamed body. To simplify the fabricationof the fire protection element 13, the surface 32 may also form a basesurface of the fire protection element 13. The carrier component 18together with the foamed body forms the fire protection element 13. Dueto the grid structure, the ash crust holds very stably in the event offire to the rest of the fire protection element. In addition, the entirefire protection element 13 is imparted with a greater mechanicalstrength.

FIG. 7 shows another embodiment of the carrier component 18, which isdesigned to be wavy in this case and this wave shape is accommodatedcompletely in the foamed body. This wave shape, which may beaccommodated transversely or longitudinally in the foamed body, providesvery stable support for the carrier component in the body, which is alsobeneficial for supporting the ash crust. Namely, if the ash crust fallsaway partially so that the carrier component is exposed or subjected totoo much thermal stress, the entire carrier component does not fall offor burn off abruptly, but only a portion thereof. The remaining partcontinues to be available as a support via the new crust that thenforms.

An annular carrier component 18 is used in FIG. 8, which runs near tothe outer sides 15. In this case, a carrier component is not provided inthe region of the upper or lower side 14 or 16. The threads of this gridstructure as well may be aligned in a different manner; they do not haveto extend parallel to the main extension direction (circular direction).Incidentally, this may also apply to the embodiment according to FIG. 7,in which a grid structure (e.g., a fabric) is provided. Variousproperties associated with the carrier component with respect to FIG. 6may also be present with respect to other embodiments.

In the case of the embodiment according to FIG. 9, several carriercomponents 18, 18′ are provided, and namely in the form of carriercomponents running kinked or bent in a V-shaped manner, which arepartially slotted so that they may be inserted into one another. Thisproduces a type of cross structure. In this case as well, just like withthe other embodiments, the carrier component 18, 18′ is completelyaccommodated in the foamed body.

Although some embodiments contemplate that the carrier component iscompletely embedded in a foamed body or other structure, otherembodiments contemplate that only a portion of the carrier component isembedded in the foamed body or other structure. Still other embodimentscontemplate that the carrier component is mostly on the outside of thefoamed body or other structure.

Although, at times, described as non-rigid carrier components, someembodiments contemplate using rigid carrier components. Rigid componentscan improve positioning thereof when introducing the flowing mass and/orduring the subsequent foaming.

Some embodiments provide a rigid design that can provide the carriercomponent with an additional structure or an additional supportingsubstance, for example, in that the previously flexible carriercomponent is shaped and then brought to a permanent shape via metalsupports or plastic sheathing.

In the event of fire, the carrier component can act as a reinforcementby making the layer of ash more stable on the one hand, i.e., bystrengthening the bond between the layer of ash and the unburned portionof the fire protection element so that the fire protection elementwithstands stress such as, for example, in the so-called hose streamtest (in accordance with the ASTM test standard). On the other hand, thecarrier component can make sure that the intumescence does not takeplace in an unrestrained and undirected manner, but a compression andtherefore a greater stability of the layer of ash are achieved by thediminished intumescence. In addition, when using the fire protectionelement as a ceiling bulkhead, the carrier component can prevent thelayer of ash from falling off, whereby the fire element remains stablefor a longer period of time.

Some embodiments provide that additional auxiliary means for externalsupport of the fire protection element are not provided. As a result,the production and installation of the fire protection element can besimplified.

Some embodiments provide that no additional top layers or the like beaffixed on the outer side of the fire protection element.

Some embodiments provide that the flat sides of a thin, flat carriercomponent 18 are the sides of the largest surfaces; referring to FIG. 6,the upper and lower sides for the section 32, and in terms of section 30the inner and outer sides.

While particular elements, embodiments, and applications of the presentinvention have been shown and described, it is understood that thepresent invention is not limited thereto because modifications may bemade by those skilled in the art, particularly in light of the foregoingteaching. It is therefore contemplated by the appended claims to coversuch modifications and incorporate those features which come within thespirit and scope of the present invention.

1. A line element lead-through sealed against fire and flue gas forcomponent openings, said line element lead-though including: a moldedelement configured as a sleeve of an elastic deformable intumescentmaterial that is closed on at least one side with the characteristicthat the opening cross section of the sleeve corresponds to maximum 60%of the cross section of the component opening, wherein embedded withinthe molded element is a support structure.
 2. The line elementlead-through according to claim 1, wherein the support structureincludes a grid structure that is formed of at least glass fibers. 3.The line element lead-through according to claim 1, wherein the supportstructure includes a fabric or a mat.
 4. The line element lead-throughaccording to claim 1, wherein the support structure is completelyembedded in a foamed body of the molded element.
 5. The line elementlead-through according to claim 1, wherein the support structure isflexible.
 6. The line element lead-through according to claim 1, whereinthe support structure is rigid.
 7. The line element lead-throughaccording to claim 1, wherein the support structure is completelyembedded in the molded element.
 8. The line element lead-throughaccording to claim 1, wherein, when a first portion of the moldedelement is burned into an ash crust, the support structure structurallyconnects the ash crust to a second portion of the molded element that isunburned.
 9. The line element lead-through according to claim 1, whereinthe support structure restrains an expansion of the elastic deformableintumescent material.
 10. The line element lead-through according toclaim 1, wherein the molded element is configured as one piece from theelastic deformable intumescent material.
 11. The line elementlead-through according to claim 1, wherein the molded element isconfigured as a truncated cone, and wherein the support structure isconfigured as the truncated cone.
 12. The line element lead-throughaccording to claim 1, wherein the molded element is configured as acylinder, and wherein the support structure is configured as thecylinder.
 13. The line element lead-through according to claim 1,wherein the molded element is made of at least a polyurethane foam withintumescence capability.
 14. The line element lead-through according toclaim 1, wherein the molded element is provided on its face surface witha flange-like edging that points radially outward.
 15. The line elementlead-through according to claim 14, wherein the support structure doesnot extend into the flange-like edging.
 16. The line elementlead-through according to claim 1, wherein the molded element is closedat its cover surface in order to form a seal.
 17. The line elementlead-through according to claim 16, wherein the material of the seal isthinner, at least in some areas, than the rest of the molded element.18. The line element lead-through according to claim 17, wherein thethinner areas of the seal also have specified breaking points.
 19. Theline element lead-through according to claim 16, wherein the seal isconfigured as a membrane.